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Abstract:

A vacuum insulation element, which consists of a multi-layer
configuration of at least two molded plates, that can be subjected to a
vacuum, wherein the molded plates in each case have a surrounding edge
region which in each case form a sealing surface, wherein the sealing
surfaces of the molded plates are hermetically bonded together in the
assembled state thus forming a sealing frame, such that a cavity between
the, at least two, molded plates is sealed in a manner that is
vacuum-tight, and the structure of the, at least two, molded plates
distributes the atmospheric pressure which is applied to the multi-layer
configuration when subjected to a vacuum such that the specified
structure remains stable, wherein the molded plates have numerous molded
structural elements in the shape of projections and depressions which
face in opposite directions from the molded plates and the projections,
or respectively, depressions which face the other plate respectively rest
against each other thereby forming a grid of support points when
subjected to a vacuum, and the projections, or respectively, depressions
which face away from the other plate respectively form numerous cavity
cells which can be subjected to a vacuum between the support points,
wherein the cavity cells are connected in such a manner that they
communicate with one another, and as a whole, form the cavity.

Claims:

1. A vacuum insulation element (1) that includes: a multi-layer
arrangement which can be subjected to a vacuum which contains at least
two molded plates (2, 3), wherein the molded plates (2, 3) have, in each
case, a surrounding edge region (7) which, in each case forms a sealing
surfaces (13), wherein the sealing surface (13) of the molded plates (2,
3) are hermetically bonded to each other in the assembled state thus
forming a sealing frame (12), such that a cavity between the, at least
two, molded plates (2, 3) is sealed in a vacuum-tight manner, and wherein
the structure of the, at least two, molded plates (2, 3) distributes the
effective atmospheric pressure in such a manner on the molded plates (2,
3) when in the voided state that the specified structure remains stable,
wherein the molded plates (2, 3) have numerous molded structural elements
which extend in opposite directions from molded plates in the form of
alternating projections (4) and depressions (5) and wherein the
projections (4) of the first (2) of the two plates and the corresponding
depressions (5) of the second (3) of the two plates lying on top of each
other form opposing point positions formed out of plate material, which
rest against each other in the voided state thus forming a dot-grid of
support points and wherein the depressions (5) of the first plate (2) and
the corresponding projections (4) of the second plate (3) point away from
each other forming numerous cavity cells (9) between the support points
which can be subjected to a vacuum, wherein the cavity cells (9) are
interconnected such that when taken as a whole, form the cavity.

2. A vacuum insulation element (1) according to claim 1, characterized in
that the projections (4) and the depressions (5) of both plates (2, 3)
are molded from the respective plates in a dome-like shape in two
dimensions and the dome-like projections (4) and the dome-like
depressions (5) are arranged in an alternating manner in both dimensions
of the plane of the plate in such a manner that the dome-like projections
(4) are in each case neighbored by dome-like depressions (5) in both
dimensions of the plane of the plate on each side.

3. A vacuum insulation element (1) according to claim 1 or 2,
characterized in that the dome-like depressions (5) of the first plate
(2) and the corresponding dome-like projections (4) of the second plate
(3) form molded point positions from plate material between the which, in
each case, one of the cavity cells (9) is formed.

4. A vacuum insulation element (1) according to claim 1, characterized in
that a saddle point (30) is located in each case on each of the molded
plates (2, 3) between two neighboring projections (4).

5. A vacuum insulation element (1) according to claim 1, characterized in
that the multi-layer configuration which can be subjected to a vacuum has
one or more molded installation edges (18) which can be attached to the
object which is to insulated or a frame structure (22) such that the
multi-layer configuration in the installed state is separated at a
distance from the object or the frame structure (22).

6. A vacuum insulation element (1) according to claim 1, characterized in
that the cavity cells (9) which form the cavity between the supported
regions have a dome-like structure.

7. A vacuum insulation element (1) according to claim 1, characterized in
that the molded plates (2, 3) are identically structured and connected in
a mirror symmetric manner.

8. A vacuum insulation element (1) according to claim 1, characterized in
that the molded plates (2, 3) have pyramid shaped structures.

9. A vacuum insulation element (1) according to claim 7 or 8,
characterized in that the mirror symmetrically configured molded plates
(2, 3) have structures of rows of four-sided pyramids (16, 17) having a
square base which abut on opposite sides of the bases and wherein the
peaks of the pyramid rows (16, 17) point alternately upwards and
downwards from the plane of the plate and the bases abut at opposite
sides and the pyramid rows (16, 17) are arranged next to each other such
that the peaks of the pyramids alternately point upwards and downwards
and the bases of neighboring pyramid rows lie in a common plane.

10. A vacuum insulation element (1) according to claim 9, characterized
in that three or more identical, molded plates (2, 3, 20) are connected
to each other in a mirror symmetrical manner such that on a face-up
positioned plate (2) a face-down positioned plate (20) is placed and on a
face-down positioned plate (20) a face-up positioned plate (3) is placed,
such that between two neighboring plates, in each case, a cavity is
formed and the cavities lying on top of each other are offset.

11. A vacuum insulation element (1) according to claim 1, characterized
in that the sealing surfaces (13) of the molded plates (2, 3, 20) are
bonded together with airtight glue or that the molded plates are welded
together along the sealing frame (12) in an airtight manner.

12. A vacuum insulation element (1) according to claim 1, characterized
in that the vacuum insulation element (1) has at least one valve or an
integrally molded suction nozzle (11), with which the connected cavity
cells (9) between the molded plates (2, 3, 20) can be subjected to a
vacuum by means of a vacuum pump, or inflated.

13. A vacuum insulation element (1) according to claim 9, characterized
in that the vacuum insulation element (1) consists of at least three
molded plates (2, 3, 20) wherein the individual molded plate (20), or
numerous molded plates (20) which are located between the two outer
molded plates (2, 3), have at least one opening in each case which
enables the voiding or inflating all cavities of the vacuum insulation
element (1) by means of a single valve or and integrally molded suction
nozzle (11).

14. A vacuum insulation element (1) according to claim 1, characterized
in that between the, at least two, molded plates (2, 3) an air permeable
intermediate plate is inserted, wherein the intermediate plate enables a
higher production tolerance in that the opposing supporting projections
(4) and depressions (5) do not need to be exactly placed on top of each
other, in order to ensure that the specified structure remains stable in
the voided state.

15. A vacuum insulation element (1) according to claim 1, characterized
in that on one of both of the outwards facing surfaces of the outer
molded plates (2, 3) of the vacuum insulation element (1) a cover plate
(14, 15) or a cover foil is applied.

16. A vacuum insulation element (1) according to claim 15, characterized
in that the cover plates (14, 15) or the cover foil consists of a
transparent material is attached to the outer surface of the outer molded
plate in such a manner that it does not allow dust to enter.

17. A vacuum insulation element (1) according to claim 1, characterized
in that a first molded installation edge (18) on one side of the vacuum
insulation element (1) extends beyond the outermost projecting structural
element and is attached to the object to be insulated, wherein the vacuum
insulation element (1) only touches the object to be insulated at the
installation edge (18).

18. A vacuum insulation element (1) according to claim 1, characterized
in that a first installation edge (18) on one side of the vacuum
insulation element (1) extends beyond the outermost projecting structural
element and serves for the installation on the object to be insulated,
and a second molded installation edge (18) on the other side of the
vacuum insulation element (1) extends beyond the outermost projecting
structural element and enables the installation of a covering or coating.

19. A vacuum insulation element (1), according to any claim 1, which
includes: a multi-layer configuration which can be subjected to a vacuum,
consisting of at least two molded plates (2, 3), wherein the molded
plates (2, 3) in each case have a surrounding edge region (7) which in
each case forms a sealing surface (13), wherein the sealing surfaces (13)
of the molded plates (2, 3) are hermetically bonded together in the
assembled state thereby forming a sealing frame (12), such that a cavity
is sealed between the, at least two, molded plates (2, 3) which is
vacuum-tight, and wherein the structure of the, at least two, molded
plates (2, 3) distributes the atmospheric pressure affecting the
multi-layer configuration of the molded plates in the voided state such
that the specified structure remains stable, wherein the molded plates
(2, 3) have numerous structural elements of alternating projections (4)
and depressions (5) which extend in opposite directions from the molded
plates (2, 3) and in the voided state the projections (4) or
respectively, depressions (5), which respectively facing in the direction
of the other plate, rest against each other, thereby forming a grid of
support points, and the respective projections (4) or respectively,
depressions (5) facing away from the other plate form numerous cavity
cells (9) between the support points which can be subjected to a vacuum,
wherein the cavity cells (9) are connected in such a manner that they
communicate with one another, forming a cavity as a whole.

Description:

FIELD OF THE INVENTION

[0001] The present invention concerns in general an insulation element and
in particular a vacuum insulation element consisting of numerous molded
plates arranged vertically, wherein the spaces between the molded plates
can be subjected to a vacuum.

BACKGROUND OF THE INVENTION

[0002] In times of increasing energy costs, there is a strong interest in
various fields for the possibility of conserving energy or using said
more effectively. One possible measure in areas which use a great deal of
energy such as thermal insulation is to improve the effectiveness of the
energy used wherein needless energy loss is avoided. In particular, the
cooling and heating of devices (e.g. refrigerators and ice-chests,
boilers, hot-water tanks--e.g. for solar panels, washing machines),
buildings or vehicles is energy-intensive, wherein frequently the problem
exists that insulation requires more space than is available.

[0003] Furthermore, there is a desire for upgrading techniques wherein the
existing devices, buildings or vehicles can be better insulated
retroactively.

[0004] Various systems are known for insulating devices or buildings. The
patent specification DE 689 28 547 T2 describes, for example, an
ultra-thin compact vacuum insulation material which consists of thin
metal plates welded together in an airtight manner. In order to avoid
collapse of the plates when subjected to a strong vacuum, spacing
elements are placed between the plates. In accordance with the invention,
spacing elements can be glass or glass-ceramic spheres or a thin (glass)
textile with projections, e.g. spheres or rods. In particular, the
positioning, in accordance with the invention, of the spheres is however
labor intensive and requires numerous additional procedural steps in the
production of said.

[0005] The patent specification DE 691 22 249 T2 discloses a very similar
technology which is distinguished in that it makes use of a single
spacing element consisting of a single piece instead of numerous
individual spacing elements. The spacing element in accordance with the
invention consists thereby of a thin, rigid support panel which separates
the walls of the thermal insulation plate to be voided with numerous
projections. It is also possible to use multiple panels of this type
stacked on top of each other. The walls and support panel thereby consist
of different materials, specifically metal and a material having a lower
thermo-conductive property (e.g. glass coated with enamel).

[0006] These thermal insulating plates have the disadvantage that they are
relatively expensive to produce as a separate production of plates and
support panels of different materials is required. Furthermore,
comparatively heavy materials are uses.

[0007] As a representative of other patents in this field, for the sake of
completeness, reference is made to the EP 1 475 486 B1, which discloses
vacuum insulation panels. The vacuum insulation panels according to the
invention consist of a flat thermal insulating layer (foam, fibrous
material, or microporous insulating material) with a casing of a metallic
foil which is welded in an airtight manner and voided. The panels are
parallelepiped such that they may be placed next to each other without
gaps, despite the welding seams.

[0008] Due to the thin walled casing of the panels with metallic foil,
these insulation elements are vulnerable. Already in the installation
phase the metallic foil can be easily damaged when being glued or in
extensive foaming constructions, wherein the vacuum is sacrificed. It is
also problematic that insulation elements of this type have a relatively
large dimensional tolerance.

[0009] Double walled nucleus elements subjected to a low vacuum are known
from the OS 23 49 401, with which, for example, pyramidal elevations can
be formed lying between their linear support strips. The elements are
supported by ridges and cushions, wherein the production of the elements
and the connecting of said seems to be quite complicated and thereby
expensive. Furthermore, thermal stress and/or displacement could occur,
such that an arrangement of this complexity would appear to be delicate
and subject to damage. It is also not clear that such an arrangement is
sufficiently durable.

SUMMARY OF THE INVENTION

[0010] The present invention therefore has the basic objective of
providing a simple, cost-effective vacuum insulation element which, on
one hand has high thermal insulation properties and is light, stable,
sturdy and of reasonable dimensions, and on the other hand, as part of
the original equipment, but also for retrofitting, can be easily
installed without a great deal of expense.

[0011] The objective of the invention is achieved through the object in
claim 1; advantageous embodiments of the invention are defined in the
dependent claims.

[0012] In accordance with the invention, a vacuum insulating element which
can be voided is provided which consists of at least two molded plates
wherein the individual plates are hermetically connected by means of at
least one encompassing sealing frame and at least one encompassing
sealing surface.

[0013] In the framework of this invention, molded plates are understood to
be morphologically structured objects, which for the most part, however,
have a sheet-like shape. This sheet-like shape can be bowed in order that
the vacuum isolation element can be fitted to rounded surfaces. For
example, by this means, the vacuum insulation element can be fitted to a
curved skylight.

[0014] In accordance with claim 1, the molded plates display numerous
structural elements when laid flat, which project alternately upwards and
downwards, or in opposite directions respectively, which deviate from the
plane of symmetry in the plates. For this, structural elements which
project downwards are referred to as depressions and structural elements
which project upwards are referred to as projections, wherein it is clear
that "upwards" and "downwards" are not absolute directions in space as
the elements can be used in any orientation and moreover are
mirror-symmetrical. The shape of these structural elements is tailored to
the needs, on one hand regarding stability, and on the other hand, in
regard to the least possible heat transfer through the vacuum insulation
element. A stable form with limited heat transfer can encompass the
statics of dome oriented structural elements, e.g. having curved
cross-sections. It is also possible however, to have structural elements
which, in conjunction with neighboring plates, display a honeycombed
cross-section.

[0015] The arrangement of the individual structural elements of the molded
plates is such that when they lie on top of each other, the projections
are directly opposite the depressions of neighboring plates such that
these integral, in particular, dome shaped, structural elements are
supported against each other when assembled and such that they serve as
points of support between neighboring molded plates. In other words, the
projections, or respectively, depressions which face neighboring plates
abut projections, or respectively, depressions, of the neighboring plate
which are facing said plate. The points of support are distributed in a
grid, wherein the term "grid" can also refer to irregular distributions.
The other projections or depressions which are facing away from the
other, neighboring plate, together with the projections or depressions of
the other neighboring plate, which are facing away from the first plate,
form cavity or box section cells, which are connected to each other, or
communicate with one another. The collective cavity cells between the
neighboring plates form thereby a common cavity, which is subjected to a
vacuum. In this manner there is always one cavity less than the number of
plates used. When four molded plates are used, there are, accordingly,
three cavitys, and when two molded plates are used, one cavity is formed.

[0016] In other words, the projections and depressions of the first
(bottom) plate and the corresponding depressions of the second (upper)
plate form point shaped positions of plate material which support each
other when a vacuum has been applied, thereby forming an integral
point-grid of support points. The point-grid has the advantage of reduced
surface contact, thus keeping the thermo-conductive property at a
minimum. In this context, "point position" and "point-grid" are clearly
not meant in the mathematical sense, but rather, the "points" form
contained surfaces which are as small as possible, e.g. of one or a few
square millimeters. The advantage over linear shaped strips is, in
particular, that the individual cavity cells between the dot shaped
support points are connected such that they communicate directly with
each other already, without the need for additional spacing elements, and
an alternating structure of this type is very stable.

[0017] The molded depressions of the first plate and the corresponding
molded projections of the second plate face away from each other, thus
forming the numerous cavity cells which can accommodate a vacuum between
the support points, wherein the cavity cells are connected in such a
manner that they communicate with one another, collectively forming the
entire cavity which is to be voided.

[0018] The projections and depressions of both plates are shaped in two
dimensions in a dome-like manner from the respective plates thereby and
the dome-like projections and dome-like depressions alternate in the two
dimensions of the plane of the plates such that the dome-like projections
are encompassed directly on all four sides, or respectively, in both
dimensions of the plane of the plate on each side, by dome-like
depressions in each case. Along the hypothetic line connecting the peaks
of the dome-like projections, projections and depressions alternate
accordingly in both dimensions, perpendicular to each other, of the plane
of the plate, in a manner similar to that of a waffle.

[0019] In particular, the depressions of the lower, first plate and the
corresponding projections of the upper, second plate also form point
positions made of the plate material, between which, in each case, one of
the cavities is formed. As a result, there is a valley between two
neighboring projections on each of the molded plates, forming a saddle
point. The saddle points are encompassed therefore, on both sides in one
dimension of the plane of the plate, by projections and in the dimension
of the plane of the plate, perpendicular to this, by depressions.

[0020] In particular, the molded plates substantially have a uniform
thickness for the most part, where the depressions of the one side of a
plate also form the projections of the other side of said plate.

[0021] In order to obtain a good degree of thermal insulation, the hollow
spaces are subjected to a vacuum. The collapsing of the vacuum insulation
element as a result of the application of a vacuum is thereby
advantageously avoided as a result of the structure of the molded plates.
The molded plates are therefore constructed in such a manner,
advantageously, such that the atmospheric pressure applied to the molded
plates after they have been voided is distributed such that they maintain
the predefined structure, or respectively, the structure is not
significantly compressed. Because the shape of the vacuum insulation
element is only minimally altered by the vacuum, it is advantageously
possible to produce vacuum insulation elements with very precisely
defined dimensions.

[0022] In particular, in this respect, specific structures of the molded
plates are preferred, which are oriented on the static solutions for
arches known from architecture. A particularly preferred embodiment of
the invention makes use, therefore, of a dome-like structure for the
cavity cells between the supported regions, or respectively, an arch-like
depression structure is created. The supported regions thereby form
pillars, which support the arches. Accordingly, the plates exhibit a
structure of arched domes in two dimensions alternating in opposite
directions; in other words, they have a structure similar to an egg
carton. Molded plates of this type are also referred to in some cases as
studded sheets.

[0023] The molded plates may also contain bridge-like structural elements
which fulfill the stability requirements. The mutually supporting
structural elements form thereby the buttresses of these "bridges" and
the cavity cells lying between them form "archways." In particular, the
buttresses may be connected to each other by archways, wherein the
buttress is the starting point for numerous, as an example, oriented at
right angles to each other, bridges, and the bridges serve as foundation
for the arch construction which spans the bridges.

[0024] A preferred embodiment of the invention intends that the vacuum
insulating element is voided as desired and then can be re-inflated. This
can be achieved by implementation of valves. If an embodiment of this
type is used, for example, for the insulation of buildings or
greenhouses, a vacuum pump can be installed advantageously in the
building, wherein the vacuum insulation elements can be voided as needed
when insulation is desired. If insulation is not desired, for example
when thermal convection from sunlight is to be made use of, the vacuum
insulation elements can be re-inflated.

[0025] If, on the other hand, a variable insulation of this type is not
necessary, in particular if the vacuum insulation elements according to
the invention are to have a permanent insulating effect, such as is the
case, for example, with refrigerating devices, then the installation of
comparably expensive valves and vacuum pumps can be eliminated. In a
further advantageous embodiment of the invention, for such cases an
integrally molded suction nozzle is incorporated in at last one of the
plates, which can be permanently closed after the vacuum has been
applied.

[0026] In order to ensure a simple and speedy voiding of the individual
vacuum insulation elements, the molded plates or the individual molded
plate have/has at least one opening between the plates on the edges in
each case, which enables the simultaneous voiding of all hollow spaces,
respectively, located between neighboring plates of a vacuum insulation
element, wherein only one valve, or respectively, an integrally molded
suction nozzle is needed for each vacuum insulation element.

[0027] The molded plates, from which the vacuum insulation element is
constructed, may be deep-drawn or in a single piece, injection molded
from synthetic plates, which has the combined advantage of using cost
efficient basic materials and inexpensive production methods. In this
respect, PMMA, PVC, PETG, polycarbonate, epoxy, polyester, polyethylene,
polystyrene, fiberglass and mixtures of these materials have been shown
to be particularly suited for this purpose.

[0028] Sandwich structures are however also possible, in which the plates
have different layers. This is advantageous in particular when materials
are to be used that are only partially, i.e. for certain gases, airtight.
A combination of materials of this type can, for example, consist of PET
and polyethylene. Vapor deposition or lamination of synthetic plates with
thin metallic layers or metal foils, or, where applicable, with an epoxy
layer, can generally improve the sealing properties of synthetic
materials. Vapor deposition with metallic layers can also at least serve
in part for the reflection of infrared thermal radiation, thereby
enhancing the insulating effects of the vacuum insulation element.
Particularly cost efficient, for example, is the use of polystyrene
sheets which are sealed with an epoxy which contains metallic substances.

[0029] Furthermore, thin glass-type, glass ceramic or ceramic molded
plates, which are coated with one or more of the above specified
synthetics in order to ensure that they are gas-tight, may be used. In
this respect, metallic coatings are also conceivable. The specified
materials have the advantage that large quantities can be produced in a
cost-effective manner.

[0030] Furthermore, the molded plates can be lacquered regardless of their
basic material, not only to ensure sealing against gas infiltration but
also for aesthetic reasons.

[0031] Plastic is a particularly preferred material because its properties
with respect to the present invention are advantageous. Important in this
regard is the low weight in relation to the high stability as a result of
the construction according to the invention. The vacuum insulation
elements in accordance with the invention are much lighter in comparison
to insulation elements known from the prior art. This low weight of the
basic plastic material is of particular significance due to the
integrally molded structural elements. Many insulation elements known
from the prior art incorporate filler material of various types in order
to avoid collapse when the element is subjected to a vacuum. These filler
materials may be necessary in substantial quantities and lead to the
vacuum insulation element having a not insubstantial weight. For the
insulation of building facades, for example, this can be disadvantageous,
because the vacuum insulation elements must be installed with a
correspondingly supportive foundation structure. In accordance with the
invention, these types of filler material for filling and stabilizing the
hollow spaces are not necessary. As a result of the comparatively lower
weight of the vacuum insulation element, it is possible to implement,
advantageously, a light construction, which requires a less complicated
support structure and attachment measures than is the case with
conventional insulation elements.

[0032] Furthermore, transparent plastic may be used in order that the
vacuum insulation elements allow for the passage of light thus making it
possible for use in areas where light must be allowed to pass through
them. This is, for example, intended for use where skylights or
greenhouses are to be insulated.

[0033] Furthermore, plastics have the advantage that they can be extremely
stable at low weights. It is possible to produce stable and relatively
robust vacuum insulation elements using relatively thin plates in the
range of <2 mm-5 mm, preferably 0.5 mm-3 mm. Lower material costs are
not only advantageous regarding lower weights, but also enable a more
cost-effective production.

[0034] In accordance with another advantageous embodiment, the molded
plates can be made of metal sheets, preferably stainless steel, due to
its low thermal conductive properties. This embodiment is useful when the
stability of the vacuum insulation element is a priority.

[0035] If the molded plates of the vacuum insulation element according to
the invention are made of plastic, they can be simply glued together or
welded at the molded surrounding sealing surface, wherein they form a
sealed chamber as a whole. Without loss of generality, ultra-sound
welding, thermal bonding in general or solvent bonding as well, are
suitable methods for this. If the molded plates are made of metal sheets,
they are preferably welded together, brazed, or soldered along the
sealing frame. It is advantageous that all of these processes are easy to
implement, wherein the person skilled in the art has the necessary
knowledge regarding how an airtight connection of the individual plates
to one another can be accomplished.

[0036] With vacuum insulation, the sustainment of the vacuum is necessary
for the insulation to be effective over a long period of time. This
problem is particularly difficult to solve if, as is frequently the case
with the prior art, the outer cover of the individual vacuum insulation
elements can be damaged. There are, for example, vacuum insulation
elements from the prior art which consist of Styrofoam or foam cores
coated with a metal foil in which the pores are subjected to a vacuum. To
save weight, the metal foil used is frequently very thin, resulting in
the outer cover being subject to damage and the insulation elements must
be installed in a complex manner in frames packed with foam material.

[0037] In a particularly preferred embodiment of the invention, the vacuum
insulation element has one or more molded assembly edges which enable the
vacuum insulation element to be attached to the object which is to be
insulated or to a framework construction. The integrally molded assembly
edges eliminate the need for awkward constructions in order to safely,
and without the risk of injury, install the insulation elements. In this
manner, the assembly edges according to the invention can be designed as
mounting brackets, such that the vacuum insulation elements can be
installed directly on the object to be insulated, e.g. screwed onto a
wall, in an advantageous manner.

[0038] Another preferred embodiment of the invention therefore has one or
more molded assembly edges of this type, which extend beyond the
outermost extending structural elements. A construction of this type
enables on the one hand, the installation of the elements directly on the
object to be insulated, but on the other hand, prevents surface contact
between the insulation and the object to be insulated. This design has
the advantage that contact between the object and the insulation is
extremely limited, and thereby the heat flow between both objects is
further limited and the insulating effect is increased.

[0039] A lining or covering can be applied to extra molded assembly edges
which extend beyond the outermost projecting structural elements on the
side opposite of the installation side. On one hand, this simply serves
to hide said, and on the other hand, they can be designed such that they
present a foundation for further measures. In this respect a foundation
for the application of stucco, for example, is a possibility.

[0040] If the vacuum insulation element is not extensively coated, e.g. if
the passage of light is necessary, cover panels or cover foils--where
applicable, transparent--can be applied to one or both of the molded
plates at the edges of the vacuum insulation element. Particularly
preferred is that the covering is bonded in an airtight manner to the
outwards facing surface of the plate on the edge, in order to avoid
optical detractions as a result of the infiltration of dust particles
between the vacuum insulation element and the covering.

[0041] Another preferred embodiment of the invention enables the
attachment of the vacuum insulation element using mounting devices by
means of openings which extend through the cavity. A mounting structure
of this type can be created using, for example, integrally molded tubes
which run through the completed insulation element. The molded tubes can
be combinations of different tube sections, wherein the individual tube
sections extending from the molded plates that they run through, are
molded. As an example, with a triple layered construction the tube
sections of a first and second plate, which form a cavity in this region,
can be shaped like a three-dimensional tube, while the tube section of a
third plate, which abuts the second plate at a support point with a point
shaped support surface, can simply consist of a hole in the plate. When
these three sections are placed together, a continuous tube extends
through the vacuum insulation element, through which the vacuum
insulation element can, for example, be bolted to a wall. The combined
tube sections are thereby connected to each other in an airtight manner,
such that the vacuum in the cavitys between the individual molded plates
is not exposed.

[0042] In accordance with another advantageous embodiment of the vacuum
insulation element according to the invention, the contact surfaces of
the mutually supporting projections and depressions of the molded plates
in the voided state are as small as possible so that the thermal
transference between neighboring plates is minimized. Particularly
preferred thereby are dot shaped contact surfaces with a diameter of
preferably less than 10 mm, and particularly preferred of less than 5 mm.

[0043] In a particularly simple and economical manner, a vacuum insulation
element according to the invention can be produced in which identically
structured molded plates are used. Because these plates have identical
structures, they can be laid on top of each other in a mirror symmetric
configuration. In order that each projection of a first molded plate lies
over a depression in a second molded plate, and the structural elements
of two neighboring plates can support each other, the plates must be
arranged such that the top of the first plate is facing the top of the
second plate, and the bottom of the second plate is facing the bottom of
a third plate, etc. etc.

[0044] In a preferred embodiment of the invention, the structural elements
are formed in the shape of a pyramid, the peaks of which alternate
between extending upwards and extending downwards.

[0045] In a very stable embodiment of the invention, the molded plates
consist of rows of four-sided pyramids with preferably a square base. A
single pyramid row consists thereby of pyramids with the peaks extending
alternately upwards and downwards and which abut on opposite sides. A
molded plate consists, in accordance with the invention, of numerous such
pyramid rows, wherein the pyramid rows are arranged next to each other,
offset such that the peaks of neighboring pyramids point in different
directions, and their bases lie in the same plane. Plates which are
shaped in this manner can be laid on top of each other in a mirror
symmetric manner, as described above and can be attached to each other in
accordance with the invention. In the completed vacuum insulation
element, the points of the pyramids of neighboring molded plates meet,
thereby providing the vacuum insulation element with its stability
against the atmospheric pressure of the surroundings after being
subjected to a vacuum.

[0046] The mirror symmetrical configuration of identically shaped plates
can also be described as a series of plates arranged as "normal,"
"inverse," "normal" [trans: "face-up," "face-down," "face-up"]. This
results in a characteristic arrangement of the hollow spaces which, due
to the predefined structure, are also identical, although due to the
minor symmetric placement are offset from each other. If the structural
elements of the molded plates also display a regular pattern, such as,
for example, the pyramid shape described above, bodies can be produced,
which can be placed together without gaps, that display a particularly
good stability.

[0047] In order that the vacuum insulation element is stable and true to
its form after being subjected to a vacuum, and the plates do not shift
in an undesired manner against each other and "slide together," the
assembly of the vacuum insulation elements requires a certain precision.
The projections and depressions of neighboring plates must come together
precisely. This need for precision can be mitigated through the insertion
of an intermediate layer in accordance with the invention, and the
"sliding together" of the molded plates when subjected to the vacuum can
be prevented. Another preferred embodiment of the vacuum insulation
element in accordance with the invention therefore contains an air
permeable, preferably flat, intermediate plate between each pair of
neighboring molded plates, which does not adversely affect the
application of the vacuum, but increases the production tolerances.

[0048] In the following, the invention will be explained in greater detail
through embodiment examples and with reference to the illustrations,
wherein identical and similar elements have in part the same reference
symbols and the characteristics of the various embodiments can be
combined.

A BRIEF DESCRIPTION OF THE ILLUSTRATIONS

[0049] FIG. 1A partially cut-away perspective view of a double layered
embodiment of the vacuum insulation element in accordance with the
invention.

[0050] FIG. 2 A cross-section of a vacuum insulation element as shown in
FIG. 1.

[0057] FIG. 9 A photograph of the vacuum insulation element in FIG.
8--subjected to vacuum.

[0058] FIG. 10 A photograph of a comparison, wherein one plate has pyramid
shaped structural elements and the second plate is not molded--not
subjected to vacuum.

[0059] FIG. 11A photograph of the comparison in FIG. 10--subjected to
vacuum.

DETAILED DESCRIPTION OF THE INVENTION

[0060] FIG. 1 shows a partially cut-away perspective view of a vacuum
insulation element 1 according to the invention, while FIG. 2 shows a
cross-section of an identically constructed vacuum insulation element 1.
The vacuum insulation element 1 is constructed of two molded plates 2, 3
which are arranged on top of each other in a minor symmetric manner. The
molded plates 2, 3 mutually support each other at selective points in
that in each case a molded projection 4 of the lower plate 2 rests
directly against a molded depression 5 of the upper plate 3, wherein
basically dot-shaped contact surfaces 6 between the lower molded plate 2
and the upper molded plate 3 result, forming the point-grid of support
points.

[0061] The vacuum insulation element 1 contains an encompassing edge area
7 which is subdivided radially at numerous points. Directly bordering the
pyramid shaped structures 7 is a surrounding frame 8 which enables a
uniform voiding of the cavity cells 9 between the two molded plates 2, 3.
A flexible region 10 is incorporated in the surrounding frame 8 which
serves to compensate for differences in height between the two molded
plates 2, 3. An integrally molded suction nozzle 11 for voiding the
cavity cells 9 is incorporated in the flexible region 10. A sealing frame
12 is obtained through the combining of the two molded plates 2, 3, which
are bonded together along the surrounding sealing surface 13 in an
airtight manner. The multi-layer arrangement, consisting of the two
molded plates 2, 3 is covered by cover plates 14, 15 both on the top and
the bottom, wherein the space between the multi-layer arrangement and the
cover plates 14, 15 is not subjected to vacuum.

[0062] The molded plates 2, 3 display a pyramid-like structure, wherein
the individual pyramids are four-sided, i.e. they have four pyramid sides
and a square base. The peaks of the pyramids are flattened. The
individual molded plates 2, 3 are constructed of rows of pyramids 16, 17.
The pyramids abut on opposite sides of their bases, which are in a common
plane. The peaks of the pyramids in a row of pyramids extend upwards and
downwards alternately such that a series of pyramids in a row results
wherein a pyramid extending upwards is followed by a pyramid extending
downwards and so on. Neighboring pyramids 16, 17 are offset by one
pyramid base in each case such that a pyramid of a first pyramid row 16
having a peak extending upwards is situated next to a pyramid of a second
pyramid row 17 having a peak which extends downwards. In other words, a
pyramid is surrounded at its base by pyramids extending in the opposite
direction. Between two projections 4, in each case there is a valley with
a saddle point 30.

[0063] The pyramids of the molded plates 2, 3 display structural elements
wherein pyramids with peaks extending upwards correspond to projections 4
and pyramids with peaks extending downwards correspond to depressions 5.
In the assembled and voided state, the projections 4 of the molded plate
2 rest against the depressions 5 of the molded plate 3. From this
construction a static is obtained which distributes the load of the
external atmospheric pressure applied to the vacuum insulation element
over the molded plates 2, 3 such that the vacuum insulation element does
not collapse, even in the voided state. Preferable in this respect are
dome-like structural elements, which are also obtained by this
pyramid-like structure.

[0064] Between the supporting regions, obtained by the projections 4 and
the depressions 5, single, interconnected cavity cells 9 are obtained,
which, when taken as a whole, i.e. the entirety between the neighboring
plates 2, 3, forms a cavity.

[0065] In FIG. 3, a triple layered vacuum insulation element 1 is shown,
of molded plates 2, 3 having an identical structure to the molded plates
2, 3 described in FIGS. 1 and 2.

[0066] However, differing from FIGS. 1 and 2, three molded plates 2, 3, 20
are arranged here on top of each other in a mirror symmetrical manner. In
this case, mirror symmetric is understood to mean that the bottom plate 2
has a "face-up" orientation, the middle plate 20 has a "face-down"
orientation, and the top plate 3 has again a "face-up" orientation. As a
result, the bottom plate 2 and the top plate 3 have a parallel
arrangement.

[0067] FIG. 4 shows a triple layered vacuum insulation element 1 like that
in the description of FIG. 3, as an outer wall covering. The illustration
is in part cut-away for purposes of clarity.

[0068] In a deviation from the embodiment described in FIG. 3, the suction
nozzle 11 for establishing the vacuum in the vacuum insulation element 1
is not integrated in the surrounding edge region 7, but instead, is
located in a depression 4 of the molded plate 3. The surrounding edge
region 7 in this preferred embodiment bent somewhat perpendicularly to
the longitudinal direction of the molded plates 2, 3 in order that two
vacuum insulation elements 1 in accordance with the invention can be
arranged next to each other without a gap. The frame region 7 extends at
the bottom of the vacuum insulation element 1 beyond the outmost extended
projecting structural elements, or, therefore, the depressions 5 of the
bottom molded plate 2 and forms there a molded installation edge 18.

[0069] The molded installation edge 18 serves for the attachment of the
vacuum insulation element 1 to the outer wall of the building 19. As is
shown in detail in FIG. 5, the vacuum insulation elements 1 have at the
top and bottom in each case an angled mounting strip 21 which can be hung
on the outer wall by means of screws 25 inserted in said. It is
understood however any other suitable mounting system is equally
acceptable.

[0070] The installation edge 18 is shaped such that the vacuum insulation
element 1 only comes into contact with the outer wall of the building 19
which is to be insulated at the installation edge 18, or respectively the
mounting strip 21. The other parts of the vacuum insulation element 1 do
not touch the wall of the building 19. An arrangement of this type
minimizes a potential heat transfer between the vacuum insulation element
1 and the building wall 19 and thereby serves to improve the insulating
effect.

[0071] FIG. 6 shows a cross-section of a triple layered vacuum insulation
element 1 which is suited for use in temperature controlled constructions
on trucks. This embodiment can also be used for insulating containers
which are intended for temperature controlled transportation.

[0072] The triple layered vacuum insulation elements 1 consist of, as is
described in FIG. 3, three molded plates 2, 3, 20 which in each case have
a differently molded installation edge 18. The installation edge 18 shown
in this illustration runs in this example expediently, perpendicular to
the surface of the plate and is shaped such that it has the largest
possible contact surface on the face of the frame construction that it is
glued to. In order to bond the vacuum insulation element permanently, to
the greatest extent possible, to the sub-structure, in this case a
U-bracket 26, all depressions of the molded plate 2 and all projections
of the molded plate 3 are glued to the frame structure 22 of fiberglass
reinforced plastic panels and the molded plates are also glued at the
dot-shaped contact surfaces to each other (glue 24).

[0073] In addition to the gluing, the vacuum insulation element 1
installed in the flooring is firmly bolted with a screw 25 to the
sub-structure of the floor, a U-bracket 26, wherein the screw 25 extends
through a tube 29 in the vacuum insulation element 1. The tube 29 is a
composite element, wherein the individual tube sections or tube
components are molded parts of the three molded plates 2, 3, 20 which,
when connected to each other, form a tube 29 extending through the vacuum
insulation element 1. The tube sections which are glued or welded
together are connected in a vacuum-tight manner such that a permanent
vacuum in the vacuum insulation element 1 can be generated. In addition,
a floor lining 23 is applied to the frame structure 21 of the floor.

[0075] FIG. 7 shows a cross-section of two vacuum insulation elements 1
according to the invention which can be moved in relation to each other
by means of a hinge 27. The vacuum insulation elements 1 are connected to
the hinge with screws 25, wherein, to improve stability, the space
between the vacuum insulation elements 1 and the lower cover plates 15 is
filled with a PU-foam 28. The installation edges 18 of the two vacuum
insulation elements 1 serve in this embodiment to produce a sealed
surface when the hinge 27, as it is shown in the illustration, is not
bent. If, in contrast, the hinge 27 is in the bent position, the
curvatures of the installation edges 18, which are fitted to each other,
on the two vacuum insulation elements 1 form a frictionless separation
along the molded installation edges 18.

[0076] Vacuum insulation elements 1 mounted on hinges, such as is shown in
FIG. 7, can be used for sectional doors, for example, in large production
halls or similar structures. The faces can deviate thereby from
perpendicular, and can, for example, as shown in FIG. 7, be rounded or
angled.

[0077] The FIGS. 8 and 9 show photographs of double layered vacuum
insulation elements 1 in accordance with the invention which are
structured in a pyramid-like manner and are arranged minor symmetrically
to one another. The molded plates are made of 1 mm thick polystyrene
plates. In FIG. 8, the insulation element 1 is shown in the inflated
state; the manometer shows a pressure of 0 bar. In FIG. 9, the same
vacuum insulation element 1 is shown, but in the voided state; the
manometer shows a vacuum of approx. -0.9 bar. The comparison of the two
photographs shows that the vacuum insulation element 1 is fully stable
even when subjected to a vacuum.

[0078] To illustrate the stability of the shape of the vacuum insulation
element 1 in accordance with the invention, the FIGS. 10 and 11 show a
comparison image consisting of a molded plate on the bottom and a plate
on top which is not molded. The plates used here are also made of 1 mm
thick polystyrene. In FIG. 10 the configuration is inflated, as can be
seen by the 0 bar reading on the manometer. In FIG. 11, the same
configuration in the voided state; the vacuum is slightly above -0.8 bar.
The upper, un-molded plate does not retain its shape when subjected to a
vacuum, but rather has "clung to" the shape of the molded plate lying
beneath it. The entire configuration is warped, and the lower right edge
is bent upwards.